Certification Services Division

1 Spencer Parade, Northampton

NN1 5AA, United Kingdom
Tel: +44(0)1604-259-056.
Fax: +44(0)1604-231-489.
E-mail: pcn@bindt.org

PCN/GEN Appendix B1.1 Issue 4

Further information concerning the content of PCN documents is available from the PCN Scheme
Manager at the above address.

SPECIFIC REQUIREMENTS FOR THE CERTIFICATION OF

PERSONNEL IN ULTRASONIC TESTING OF CASTINGS

ASSOCIATED DOCUMENTS:

Appendix B1.2 to PCN/GEN

Examination Syllabus for the Certification of Personnel in Ultrasonic Testing of Castings.

Appendix B1.3 to PCN/GEN

Specimen Examination Questions for the Certification of Personnel in Ultrasonic Testing of Castings.

CONTENTS
1. SCOPE ........................................................................................................................................... 2
2. EXAMINATION CONTENT............................................................................................................... 2
3. CERTIFICATION AVAILABLE .......................................................................................................... 3
4. RENEWAL AND RECERTIFICATION ............................................................................................... 3
5. GRADING ....................................................................................................................................... 3

The British Institute of Non-Destructive Testing is an accredited certification body

offering personnel and quality management systems assessment and certification
against criteria set out in international and European standards through the PCN
Certification Scheme.
1. SCOPE
This document prescribes the specific requirements and procedures by which personnel may be
examined and, if successful, certificated for the manual ultrasonic testing of castings. Requirements
contained in this document are supplementary to those contained in PCN General Requirements for
Certification of Personnel engaged in Non-Destructive Testing.

2. EXAMINATION CONTENT
The examination format is described in PCN General Requirements. This Appendix amplifies the
provisions of that document only where necessary.

2.1 Level 1
Except where exemptions apply (refer to PCN General Requirements), all candidates will be required
to attempt an examination comprised of the following parts:

2.1.1 General Theory of the Ultrasonic NDT method. Forty multiple choice questions to be answered
in 60 minutes. Minimum pass mark 70%.

2.1.2 Sector Specific Theory of the application of the Ultrasonic NDT method to castings. Twenty
multiple choice questions to be answered in 30 minutes. Minimum pass mark 70%.

2.1.3 Sector Specific Practical examination comprised of:

(i) preparation and calibration of testing equipment for use (this may involve system
sensitivity and control checks).
(ii) ultrasonic thickness measurement of eight samples of varying thickness and two
attenuation measurements to provided NDT instructions.
(iii) reporting the results in a prescribed manner on proforma report sheets.
The total time allowed for the practical examination is four hours. The minimum pass mark for the
practical part is 70% per sample tested and 70% for the NDT instruction (failure to detect and report a
reportable discontinuity in any one sample, or failure to produce an acceptable NDT instruction, will
result in failure of this examination part).

2.2 Level 2
Except where exemptions apply (refer to PCN General Requirements), all candidates will be required
to attempt an examination comprised of the following parts:
2.2.1 General Theory of the Ultrasonic NDT method. Forty multiple choice questions to be answered
in 60 minutes. The minimum pass mark is 70%.
2.2.2 Sector Specific Theory of the application of the Ultrasonic NDT method to the testing of castings.
Thirty multiple choice questions (ten of which will cover the basic casting process and associated
defects) to be answered in 45 minutes. The minimum pass mark is 70%.
2.2.3 Sector Specific Practical examination comprising:
(i) preparation and calibration of testing equipment for use (this may involve system
sensitivity and control checks).
(ii) testing four samples (selected by the examiner) in accordance with NDT instructions
(three to be provided by the test centre, and one to be generated by the candidate
(see (iv) below) which will give, where appropriate, sensitivity levels and reporting
thresholds.

(iii) reporting test results in a prescribed manner on proforma report sheets.

(iv) preparing a detailed NDT instruction (suitable for level 1 personnel to follow) for the testing of
one of the above samples to a provided procedure, code, standard or specification, and to prove
the instruction by application.
The total time allowed for the sector specific practical examination is eight hours, and the minimum
pass mark is 70% in each sample (failure to detect and report a reportable discontinuity in any one
specimen will result in failure of this examination part), and 70% for the NDT instruction.

PCG/GEN Appendix B1.1 2 of 3 dated 16th December 2004

2.3 Level 3
Except where exemptions apply (refer to PCN General Requirements), all candidates will be required
to attempt an examination comprised of the following parts:
2.3.1 A Basic Examination (information on time allowed and pass marks is given in the current edition
of PCN General Requirements), comprising:
A1) Thirty multiple choice questions covering materials technology and science, covering
typical defects in a range of products including castings, welds and wrought products.
A2) Ten multiple choice questions on the content of the current edition of PCN General
Requirements for the Certification of Personnel engaged in the application of non-
destructive testing (a copy of which will be provided for use in the examination).
B) Sixty level 2 multiple choice questions on the general theory of four NDT methods.
The examination will include fifteen questions on the NDT method in which the
candidate is presently seeking certification, and a further fifteen on each of three other
methods selected by the candidate (N.B. at least one of the four methods examined
must be a volumetric method).
2.3.2 A Main Method examination comprising:
C1) Thirty multiple choice questions covering the general theory of the ultrasonic NDT
method.
C2) Twenty multiple choice questions covering the specific theory of the ultrasonic test
method to castings.
C3) The candidate will be required to produce a comprehensive test procedure embodying
an NDT instruction for the ultrasonic testing of a specific casting, to a provided
specification standard or code.

2.3.3 Level 3 candidates who do not hold or have not held PCN level 2 certification for the ultrasonic
testing of castings are required to successfully complete the examination described in Clause 2.2.3.

3. CERTIFICATION AVAILABLE

3.1 Level 1 Ultrasonic Testing (Castings).

3.2 Level 2 Ultrasonic Testing (Castings).
3.3 Level 3 Ultrasonic Testing (Castings).

4. RENEWAL AND RECERTIFICATION

4.1 The general rules for level 1 and level 2 renewal and recertification are fully described in PCN
document CP16, and the rules for level 3 recertification are detailed in PCN document CP17.

4.2 Level 1 certificate holders seeking recertification will be required to undertake the practical
examination detailed at Clause 2.1.3 above. The minimum overall pass mark for recertification is 80%.

4.3 Level 2 certificate holders seeking recertification will be required to undertake the practical
examination detailed in Clause 2.2.3 above. The minimum pass mark for the practical part is 70% per
sample tested and 70% for the NDT instruction (failure to detect and report a reportable discontinuity
in any one sample, or failure to produce an acceptable NDT instruction, will result in failure of this
examination part). The minimum overall pass mark for recertification is 80%.

5. GRADING
The method for composite grading of examinations will be as specified in the current edition of PCN
General Requirements.

PCG/GEN Appendix B1.1 3 of 3 dated 16th December 2004

Certification Services Division
1 Spencer Parade, Northampton
NN1 5AA, United Kingdom
Tel: +44(0)1604-259-056.
Fax: +44(0)1604-231-489.
E-mail: pcn@bindt.org

PCN/GEN Appendix B1.2 Issue 4

Further information concerning the content of PCN documents is available from the PCN Scheme
Manager at the above address.

EXAMINATION SYLLABUS FOR THE CERTIFICATION OF

PERSONNEL IN ULTRASONIC TESTING OF CASTINGS

ASSOCIATED DOCUMENTS:

Appendix B1.1 to PCN/GEN

Specific Requirements for the Certification of Personnel in Ultrasonic Testing of Castings

Appendix B1.3 to PCN/GEN

Specimen Examination Questions for the Certification of Personnel in Ultrasonic Testing of Castings.

CONTENTS
LEVEL 1 SYLLABUS ..................................................................................................................2
LEVEL 2 SYLLABUS ..................................................................................................................3
LEVEL 3 SYLLABUS ..................................................................................................................6

The British Institute of Non-Destructive Testing is an accredited certification body

offering personnel and quality management systems assessment and certification
against criteria set out in international and European standards through the PCN
Certification Scheme.
LEVEL 1 SYLLABUS

1. General Theory

1.1 Principles of Ultrasonic Testing

1.1.1 Essential features of ultrasonic testing. Generation of ultrasonic waves. Electromagnetic

transducer (piezo-electric, magnetostrictive and electrodynamic). Properties of the transducer (nominal
and working frequency, bandwidth). Effect of different transducer materials.

1.1.2 Wave properties - types of wave, vibration, waves, sound waves, continuous wave, pulse,
frequency, velocity, wavelength. Units, relationship between frequency, velocity and wavelength.

1.1.3 Principles of reflection and transmission of sound waves at perpendicular incidence. Effect of
coupling media on transmission. Acoustic impedance.

1.1.4 Principles of reflection and refraction of sound waves at inclined incidence.

1.1.5 Factors affecting angles of reflection, refraction and mode conversion.

1.1.6 Effect of reflector on echo response.

1.1.7 Generation of ultrasonic waves. Electromechanical transducer (piezo-electric, magnetostrictive

and electrodynamic). Properties of the transducer, (nominal and working frequency, bandwidth). Effect
of different transducer materials.

1.1.8 Sound field - influence of frequency, sound velocity and size of transducer. Estimate of near
field, far field and beam divergence.

1.1.9 Influence of properties of test object on sound propagation, sound velocity and attenuation.

1.2 Equipment
1.2.1 Construction and mode of operation.

1.2.2 Block diagram of an ultrasonic instrument with single and double transducer, controls and
functions of ultrasonic instrument.

1.2.3 Types of probe - normal beam, single and twin crystal, angle beam. Construction and mode of
operation.

1.2.4 Signal presentation - A, B, C scans.

1.2.5 Definition and use of decibel.

1.2.6 Scanning techniques - manual, semi-automatic, automatic.

1.3 Testing Techniques

1.3.1 Pulse-echo technique - basic principle, measured values (transmit time, echo amplitude),
advantages and limitations.

1.3.2 Contact scanning - couplant, protective layer.

1.3.3 Gap scanning - basic principle.

1.3.4 Immersion testing - basic principle.

1.3.5 Through-transmission technique - basic principle, measured value (intensity), advantages and
limitations.

1.3.6 Application of compression and shear waves.

PCN/GEN Appendix B1.2 2 of 8 dated 16th December 2004

1.4 Calibration of Testing Systems
1.4.1 Timebase calibration - normal, single and twin crystal and angle beam probes. Calibration blocks
and reference blocks. Calibration checks. Effect of different sound velocities in calibration block and
test piece. Measurement of wall thickness and flaw position using normal and angle beam probes.

1.4.2 Sensitivity and signal to noise ratio.

1.4.3 Beam width.

1.4.4 Sensitivity setting - simple methods, BWE, DAC. Effect of surface finish, geometry and
attenuation in specimen.

1.4.5 Probe index.

1.4.6 Beam angle.

1.4.7 Squint.

1.4.8 Pulse duration.

2. Sector Specific Theory

2.1 Detectability of Defects

General - advantages and limitations of the test method with regard to defect detection.
2.2 Factors Affecting the Performance of the Ultrasonic Test

2.2.1 Mechanical properties of the material, attenuation.

2.2.2 Geometry of the specimen.

2.2.3 Surface condition.

2.3 Codes of Practice and Standards

See essential reading list.

2.4 Conducting and Recording the Test

2.4.1 Routine calibration of equipment.

2.4.2 Procedure to be adopted to carry out the test.

2.4.3 Information to be recorded on the report.

2.4.4 Flaw assessment and reporting.

LEVEL 2 SYLLABUS
3. General Theory

As level 1, but in addition:

3.1 Principles of Ultrasonic Testing

3.1.1 Physical principles.

3.1.2 Behaviour of sound wave for perpendicular incidence. Acoustic impedance. Reflection and
transmission factors. Calculations of reflected and transmitted energy.

3.1.3 Behaviour of sound wave for inclined incidence. Snells Law concerning reflection, refraction and
mode conversion. Critical angles. Calculations.

3.1.4 Interpretation and prediction of boundary echoes. Time base position of mode converted echoes
under known conditions.

3.1.5 Influence on sound waves of reflector size (reflection, scatter, refraction, interference).
PCN/GEN Appendix B1.2 3 of 8 dated 16th December 2004
3.1.6 Reflection at defined reflectors. Laws concerning distance and size of backwall echo, side drilled
hole and disc reflectors. Comparison with real flaws.

3.1.7 Sound field. Calculation and estimation of near field, far field and beam spread.

3.1.8 Influence of properties of specimen on sound propagation, attenuation, cause, effect and
measurement, attenuation coefficient. Surface shape and condition. Sound velocity, cause, effect and
measurement.

3.2 Equipment

3.2.1 Probe construction and mode of operation. Special probes, double crystal angle probes, focused
probes, probes with different damping.

3.2.2 Measurement of resolving power of angle probes. Correlation between resolution, frequency,
penetrating power and damping.

3.2.3 Amplifier characteristics, broad and narrow band, logarithmic, saturation, linearity, suppression,
DAC correction.

3.2.4 Signal presentation. Deeper knowledge of automatic test systems.

4. Sector Specific Theory

4.1 Testing Techniques

4.1.1 Tandem technique. Arrangement of probes, applications.

4.1.2 Immersion testing.

4.1.3 Selection of probes to suit material conditions.

4.1.4 Through-transmission technique.

4.2 Calibration of Testing Systems

4.2.1 Timebase calibration - projected distance, shortened projected distance. Thin wall, curved
surfaces, effect of different materials.

4.2.2 Construction of reference lines and calibration of sensitivity with reference to backwall echo, side
drilled hole, flat bottomed hole. Reference block and DGS methods.

4.2.3 Measurement of the differences for surface condition and attenuation between test piece and
reference block. Correction for transfer (coupling, attenuation) correction for attenuation depending on
path length, correction for near surface defects.

4.3 Detectability of Defects

General - advantages and limitations of the test method with regard to defect detection.

4.4 Factors Affecting the Performance of the Ultrasonic Test

4.4.1 Relationship between properties of the material, condition, attenuation and sound velocity.

4.4.2 Testing of austenitic steels.

4.4.3 Selection of probe type, frequency and angle.

4.4.4 Preparation of test surface.

4.4.5 Selection of couplant and method.

4.4.6 Influence of defect type, position and orientation on detection.

PCN/GEN Appendix B1.2 4 of 8 dated 16th December 2004

4.5 Codes of Practice and Standards

See essential reading list.

4.5.1 Establishing of testing instructions considering application, equipment, technique, probes,

calibration, operation of test, recording of test results.
4.6 Conducting and Recording the Test

4.6.1 Procedure to be adopted to carry out the test.

4.6.2 Information to be recorded on the report.

4.6.3 Flaw assessment and reporting.

4.7 Interpretation of Test Results

Interpretation of test results to acceptance standards.

5. Product Technology Theory

Product technology is only applicable to level 2 and level 3 candidates. The depth of knowledge
required for this examination is given in the following syllabus but, briefly, the examination will cover:

5.1 Basic Castings Production - Crude and Finished Products

5.1.1 Ingot types narrow end up and wide end up, concast methods (continuous casting process).

5.1.2 Definition used in the production of ingots and casting.

5.1.3 Difference between ingot and concast production processes.

5.1.4 Ingot casting for further hot working, rolling, forging and extrusion.

5.2 Basic Castings Production Methods - Finished Products

5.2.1 Methods of casting:

5.2.1.1 sand casting;

5.2.1.2 die casting;

5.2.1.3 investment casting.

5.3 Basic Casting Defects (their appearance and how they are formed)

5.3.1 Shrinkage.

5.3.2 Sinks.

5.3.3 Cold shuts.

5.3.4 Porosity.

5.3.5 Laps.

5.3.6 Hot tears.

5.3.7 Cracks.

5.4 Stress Relieving

What stress relieving is and why it is carried out.

PCN/GEN Appendix B1.2 5 of 8 dated 16th December 2004

LEVEL 3 SYLLABUS

Level 3 personnel are expected to be competent to assume the responsibilities of management of an

industrial NDT facility. The PCN level 3 examination will therefore evaluate the candidate's knowledge
of the following:

Allocation of staff with appropriate certification according to customer's requirements. Supervision and
maintenance of subordinate's certification and recertification documents and records.

Compilation of records of equipment performance, repairs and maintenance; the work done and
results achieved by supervised staff. The review of reports of work done by subordinates, its periodic
validation, and the endorsement of routine reports. Review of current practices, equipment, techniques
and instructions. Maintenance of standards and text book libraries. Safe working practices and current
legislation.

The examination syllabus is as follows:

6. General Theory

Candidates will be required to be familiar with all the content of the theoretical and practical syllabi for
level 2.

7. General Theory of Other NDT Methods at Level 2

7.1 General theory at level 2, including limitations and applications, of four NDT methods. The
examination syllabi are detailed in appendices to PCN General Requirements and are obtainable from
PCN or any of its test centres.

7.2 In detail, the level 3 candidate will be required to demonstrate a knowledge of the level 2 general
theory syllabus covering the NDT method in which level 3 certification is sought and, in addition, three
others selected by the candidate from RT, UT, PT, MT, ET and VT.

8. Knowledge of PCN Requirements

A thorough understanding of the PCN criteria for certification of all levels of personnel as applied in the
current edition of PCN General Requirements for Certification of NDT Personnel.
9. Sector Specific Theory

Candidates will be required to be familiar with all the content of the specific theory syllabus for level 2
but the examination questions will be more complex. The level 3 candidate will also be expected to
demonstrate familiarity with the criteria in codes and standards covering the application of ultrasonic
testing to castings, and flaw acceptance limits, including:

9.1 Flaw sizing systems

Knowledge of the currently used systems for defect sizing dependent upon geometry and material
properties. The application of the systems for cross-sectional defect dimensions and for length of
defects.

9.2 Flaw recording systems

Knowledge of current systems for flaw recording (e.g., DGS, DAC). Recording echo height
comparisons from actual defects and their equivalent reflectors from the test block used.

9.3 Sensitivity
9.3.1 Methods of setting sensitivity for normal probes. Methods of setting sensitivity for angle probes
to obtain 'grain interference level' (or 'grass') and the recording of the equivalent calibration block
echoes, and comparison with a standard calibration block.

9.3.2 Methods of setting sensitivity using predetermined calibration block echoes and making
allowances for transfer loss and attenuation in the material.

PCN/GEN Appendix B1.2 6 of 8 dated 16th December 2004

9.4 Accuracy and Limitations

A thorough knowledge of the effective range of all types of probe beams, both of maximum and
minimum path distances. Determination of the repeatability and accuracy of the cross section of
simulated defects and of their length. Tabulation of the results achieved.

9.5 Codes for Testing and Flaw Acceptance Limits

Familiarity with the criteria in codes and standards covering the application of ultrasonics and flaw
limits. An understanding of the way in which these are applied in practice.

10. Materials Technology

This examination part will cover the product technology syllabus given earlier under level 2, but the
level 3 candidate will also require an understanding of the welding and forging processes and
associated defects.

11. Sector Specific Practical Level 2

For level 3 candidates not holding or having held a PCN level 2 ultrasonic testing certificate (castings),
the level 2 sector specific practical examination must be passed. Refer to PCN/GEN Appendix B1.1.

12. NDT Instruction Writing

For level 3 candidates not holding or having held a PCN level 2 ultrasonic testing certificate (castings),
the level 2 sector specific practical instruction writing examination must be passed. Refer to PCN/GEN
Appendix B1.1.

13. NDT Procedure Writing

13.1 Level 3 candidates will be required to produce a comprehensive test procedure for a specific
component to a provided standard or code. PCN publishes a document, CP25, for information and for
use by candidates in this open book examination.

13.2 The procedure must include acceptance levels to specified application standards, ultrasonic
(castings) operator approvals, techniques, equipment and its calibration, reference documentation, the
use of complementary NDT methods, the timing of inspection in relation to manufacturing and testing
procedures, surface condition of work, special contractual requirements, action to be taken in case of
non-compliance and reporting instructions (implementation of the procedure).

PCN/GEN Appendix B1.2 7 of 8 dated 16th December 2004

REFERENCE LITERATURE
Essential Reading - Standards and Specifications:
q BS EN 12668-1 Non-destructive testing Characterisation and verification of ultrasonic
examination equipment Part 1: Instruments
q BS EN 12668-3 Non-destructive testing Characterisation and verification of ultrasonic
examination equipment Part 3 combined equipment
q BS EN 583-1 Non-destructive testing Ultrasonic examination Part 1: General principles
q BS EN 583-3 Non-destructive testing Ultrasonic examination Part 3: Transmission
technique
q BS EN 583-5 Non-destructive testing Ultrasonic examination Part 5: Characterisation and
sizing of discontinuities
q BS EN 1330-4 Glossary of terms used in non-destructive testing. Ultrasonic flaw detection
q BS EN 12223 Calibration block No.1 for ultrasonic examination
q BS EN 12680-1 Founding. Ultrasonic examination. Steel castings for general purposes
q BS EN ISO 9000 Quality management and quality assurance standards.
NOTE. National or international standards equivalent to the above may be used as alternatives.
Training Course Notes: PCN requires candidates to have attended an approved course of
training. Accredited Training Establishments are required to provide trainees with an up-to-
date set of training course notes. These are considered essential reading.

Recommended Reading
BS 2737: Terminology of internal defects in castings as revealed by radiography.
BS 3146: Investment castings in metal.
BS 4570: Fusion welding of steel castings.
ESI 98-4: Ultrasonic testing of ferritic steel castings.
Guide to the Preparation of a Quality Manual. The Institute of Quality Assurance.
Basic Metallurgy for NDT. Edited by J L Taylor. British Institute of NDT, 1 Spencer Parade,
Northampton NN1 5AA.
Ultrasonic Flaw Detection for Technicians. JC Drury. British Institute of NDT, 1 Spencer Parade,
Northampton NN1 5AA.
Ultrasonic Testing of Materials. Krautkramer. George Allen & Unwin Limited, London.
Non-Destructive Testing Handbook: Volume 7 - Ultrasonic Testing. ASNT.
Principles and Practice of Non-Destructive Testing, edited by Dr J H Lamble. Heywood and Company,
London.
Non-Destructive Testing (second edition, 1991). R Halmshaw. Edward Arnold.
ASNT Classroom Training Handbook (originally published by General Dynamics).
ASNT Self Study Handbook (originally published by General Dynamics).
ASNT Question and Answer Book.
ASNT Level III Study Guide.
NDT Handbook, second edition, volume 3 (1985).
ASNT Student Package.
ASNT Instructor Package (overheads for training).
NOTE. Some of the above are available only in reference libraries. For information on sources of the
above recommended reading contact the Technical Secretary, The British Institute of Non-Destructive
Testing, 1 Spencer Parade, Northampton NN1 5AA.

PCN/GEN Appendix B1.2 8 of 8 dated 16th December 2004

Certification Services Division
1 Spencer Parade, Northampton
NN1 5AA, United Kingdom
Tel: +44(0)1604-259-056.
Fax: +44(0)1604-231-489.
E-mail: pcn@bindt.org

PCN/GEN Appendix B1.3 Issue 4

Further information concerning the content of PCN documents is available from the PCN Scheme
Manager at the above address.

SPECIMEN EXAMINATION QUESTIONS FOR THE CERTIFICATION

OF PERSONNEL IN ULTRASONIC TESTING OF CASTINGS

ASSOCIATED DOCUMENTS:

Appendix B1.1 to PCN/GEN

Specific Requirements for the Certification of Personnel in Ultrasonic Testing of Castings.

Appendix B1.2 to PCN/GEN

Examination Syllabus for the Certification of Personnel in Ultrasonic Testing of Castings.

CONTENTS
LEVEL 1 ....................................................................................................................................2
LEVEL 2 ....................................................................................................................................3
LEVEL 3 ....................................................................................................................................5

The British Institute of Non-Destructive Testing is an accredited certification body

offering personnel and quality management systems assessment and certification
against criteria set out in international and European standards through the PCN
Certification Scheme.
LEVEL 1
General Theory of the Ultrasonic Method
1. When a compressional wave is incident on a boundary between two media, the following type of
waves may be generated:
a) shear wave
b) compressional wave
c) surface wave
d) all of the above
2. The equation describing wavelength in terms of velocity and frequency is:
a) wavelength = velocity - frequency
b) wavelength = velocity x frequency
c) wavelength = velocity + frequency
d) wavelength = velocity/frequency
3. Sound waves above the human hearing range are referred to as ultrasonic waves and this term
embraces all vibrational waves above frequency of approximately:
a) 20 kHz
b) 2 MHz
c) 2 kHz
d) 200 kHz
4. In ultrasonic testing, the display in which pulse amplitude is represented as a displacement along
one axis and time as a displacement along another is known as:
a) A-scan
b) B-scan
c) C-scan
d) isometric projection
5. If the difference in echo height between two signals is 50%, this represents a dB difference of:
a) 20
b) 14
c) 6
d) 2

Sector Specific Theory of the Application of the Ultrasonic Method in the Testing of Castings
1. What is the maximum permitted difference between successive backwall echoes when testing
castings?
a) 5 dB
b) 10 dB
c) 15 dB
d) 20 dB
2. Reduction in backwall echo, whilst scanning a casting with a compression wave probe, may be
caused by:
a) rough surfaces
b) course grain structure
c) fine porosity
d) all of the above

PCN/GEN Appendix B1.3 2 of 9 dated 16th December 2004

3. Before testing a large steel casting, attenuation should be assessed:
a) at a single point
b) on the thinnest section
c) at a number of points
d) on the thickest section

LEVEL 2
General Theory of the Ultrasonic Method
1. The angle at which the shear component of an incident beam is refracted at 90 degrees to the
normal is called:
a) the normal angle of incidence
b) the first critical angle
c) the angle of maximum reflection
d) the second critical angle
2. As frequency increases in ultrasonic testing the angle of beam divergence of a given diameter
crystal:
a) decreases
b) remains constant
c) increases
d) varies uniformly through each wavelength
3. The fundamental frequency of a piezo-electric crystal used in ultrasonic probes is a function of:
a) its thickness
b) the velocity of sound in the crystal material
c) both A and B above
d) its diameter
4. Shear waves are generally more sensitive to fine discontinuities for a given frequency than

longitudinal waves because:

a) the wavelength is shorter

b) shear waves are not as easily dispersed in the material
c) the direction of particle vibration of shear is more sensitive
d) the wavelength of shear waves is longer
5. A linear time base is achieved when the electron beam in the CRT:
a) is deflected with constant velocity
b) is deflected with constant acceleration
c) is deflected with the same velocity as the probe movement
d) produces four echoes on the screen

PCN/GEN Appendix B1.3 3 of 9 dated 16th December 2004

Sector Specific Theory of the Application of the Ultrasonic Method in the Testing of Castings
1. Given that the velocity of a compression wave in steel is 6000 m/s, how long does it take a wave to
travel from one side to the other of a 30 mm thick section of a steel casting?
a) 5 microseconds
b) 5 milliseconds
c) 2 microseconds
d) 2 milliseconds
2. The vertical axis of the DGS diagram represents:
a) probe diameter
b) flat-bottomed hole size
c) gain
d) reflector depth
3. Defect assessment to BS 6208 for castings examination is based on:
a) zoning
b) reference reflectors
c) 20 dB drop
c) all of the above
4. Which of the following methods will quickly assess the size of large areas of shrinkage?
a) 20 dB drop
b) 6 dB drop
c) DGS
d) DAC

Casting Product Technology Theory

1. A large cavity at the centre of a cast section is most likely to be:
a) a gas hole
b) a cold shut
c) shrinkage
d) hot tear
2. Large smooth voids or porosity in a casting results from:
a) turbulent flow of metal during pouring
b) segregation of alloy constituents
c) gas evolved before and during solidification
d) hot tearing in the thick sections of the casting
3. Discontinuities which originate in the cast ingot can often be reduced by a process which closes and
welds the voids, as well as breaking up inclusions, this process is:
a) machining
b) welding
c) forging
d) cold extrusion

PCN/GEN Appendix B1.3 4 of 9 dated 16th December 2004

4. A uniform rounded cavity in a cast section is most likely to be:
a) a gas hole
b) a cold shut
c) shrinkage
d) hot tear

LEVEL 3

General Theory of the Ultrasonic Test Method

1. For piezo-electric transducers, the general relationship between frequency and transducer

thickness states:

a) frequency and transducer thickness are independent

b) thicker transducers generate lower ultrasonic frequencies
c) thinner transducers generate lower ultrasonic frequencies
d) none of the above
2. The half-angle calculation of beam spread to one tenth of the beam centre-line intensity is
calculated from:
a) sin/2 = 1.08v/Df
b) sin = 1.08D/vf
c) sin/2 = 0.56v/Df
d) sin/v = 1.22v/fD
3. The principal reason for damping the transducer in an ultrasonic probe is to:
a) reduce the applied voltage
b) enhance resolving power
c) modify sensitivity
d) reduce bandwidth
4. When using focused probes, non-symmetry in a propagated sound beam may be caused by:
a) backing material variations
b) lens centering or misalignment
c) porosity in lenses
d) all of the above
5. The 6 dB drop sizing technique should only be applied to which of the following types of
discontinuity?
a) those which are larger than the ultrasonic beam width
b) those of similar dimensions to the ultrasonic beam width
c) those which are smaller than the ultrasonic beam width
d) any size of discontinuity
6. Which of the following displays can be used to produce a plan view of a defect?
a) A-scan
b) B-scan
c) C-scan
d) D-scan

PCN/GEN Appendix B1.3 5 of 9 dated 16th December 2004

General Theory of NDT Methods at Level 2

The examination will test the candidate's understanding of the general theory at level 2 of four out of
the radiographic, ultrasonic, eddy current, magnetic particle and liquid penetrant NDT methods to
enable him/her to recognise correct application but not necessarily to specify techniques.
1. Thin sheets of lead foil in intimate contact with radiographic film increase film density because they:
a) fluoresce and emit visible light which helps expose the film
b) absorb the scattered radiation
c) prevent backscattered radiation from fogging the film
d) emit electrons which help darken the film
2. The fact that gases, when bombarded with radiation, ionise and become electrically conducting
make them useful in:
a) X-ray transformers
b) X-ray tubes
c) masks
d) monitoring equipment
3. The most effective method of demagnetisation is:

a) AC aperture coil
b) reversing and decreasing DC
c) stroking with AC yokes
d) hammering along the length of the part
4. For fine, surface breaking cracks the best magnetic particle inspection medium is:
a) dry powder, black
b) dry powder, fluorescent
c) magnetic ink, black
d) magnetic ink, fluorescent
5. Water washable penetrants require longer dwell times than solvent removable versions because of
the presence of:
a) emulsifier
b) stabiliser
c) penetrant remover
d) contaminants
6. The property of a liquid which affects the speed of flow is:
a) surface tension
b) viscosity
c) contact angle
d) a combination of all the above
7. In eddy current test systems where encircling coils are used, coupling efficiency is referred to as:
a) lift off
b) edge factor
c) fill factor
d) phase differentiation

PCN/GEN Appendix B1.3 6 of 9 dated 16th December 2004

8. When the voltage applied to a circuit and the current through the circuit both reach their maximum
at the same time, the voltage and current are:
a) additive
b) in phase
c) regenerate
d) out of phase
9. The angle at which the shear component of an incident beam is refracted at 90 degrees to the
normal is called:
a) the normal angle of incidence
b) the first critical angle
c) the angle of maximum reflection
d) the second critical angle
10. As frequency increases in ultrasonic testing the angle of beam divergence of a given diameter
crystal:
a) decreases
b) remains constant
c) increases
d) varies uniformly through each wavelength

Knowledge of the Requirements for PCN Certification

1. The minimum period of experience required to be eligible for the Level 1 Ultrasonic Practitioner
examination is:
a) 3 months
b) 12 months
c) 1 month
d) 6 months
2. Candidates who fail to achieve 70% in one section of the examination but who achieve a composite
grade of 80% or more are eligible for:

a) one retest of the failed part

b) two retests of the failed part
c) one retest of any two parts selected by the test centre
d) one retest of any two parts selected by the candidate
3. PCN candidat es shall have near distance acuity, corrected or uncorrected, in at least one eye, such
that the candidate is capable of reading:
a) Jaeger number 1 letters at not less than 30 cm
b) Jaeger number 1 letters at not more than 30 cm
c) Jaeger number 1 letters at 300 cm
d) Jaeger number 1 letters at 30 cm

PCN/GEN Appendix B1.3 7 of 9 dated 16th December 2004

Sector Specific Theory of the Application of the Ultrasonic Method in the Testing of Castings

1. A through-wall welded repair in a 30 mm thick casting is tested using a 60 degree shear wave probe
and is found to contain a flaw. If the sound path to the flaw is 85 mm, the flaw is approximately:
a) 17.5 mm from the test surface
b) 12.5 mm from the test surface
c) 1.5 mm from the opposite surface
d) 26 mm from the opposite surface
2. A plot of the variation of beam intensity along the beam axis for a given target size is:
a) a distance amplitude curve
b) used for determining the vertical extent of the beam
c) used for determining the horizontal extent of the beam
d) not useful

Materials Technology Theory

1. A large cavity at the centre of a cast section is most likely to be:

a) a gas hole
b) a cold shut
c) shrinkage
d) hot tear
2. Large smooth voids or porosity in a casting results from:

a) turbulent flow of metal during pouring

b) segregation of alloy constituents
c) gas evolved before and during solidification
d) hot tearing in the thick sections of the casting
3. Discontinuities which originate in the cast ingot can often be reduced by a process which closes and
welds the voids, as well as breaking up inclusions, this process is:

a) machining
b) welding
c) forging
d) cold extrusion
4. The failure of turbine blades at the junction of the blade and larger section where it will be attached
to the rotor can often be ascribed to cyclical stresses which are concentrated in this region. The
failure mechanism is called:

a) stress rupture
b) intergranular fretting corrosion
c) fatigue
d) hot tearing

PCN/GEN Appendix B1.3 8 of 9 dated 16th December 2004

5. Poor through thickness ductility in rolled plate, often associated with non-metallic inclusions, gives
rise to:

a) lamellar tearing
b) reheat cracking
c) uniform porosity
d) hydrogen cracking
6. The welding process which would be chosen for its rapid deposition rates, high welding speeds and
deep penetration quality joints is:

a) electroslag
b) manual metal arc
c) submerged arc
d) TIG
7. Hydrogen cracking, due to the break down of water molecules creating hydrogen which dissolves in
the weld metal and HAZ, is most likely to occur in which of the following welding processes?
a) TIG
b) MIG
c) SAW
d) MMA
8. Poor forging temperature or too great a reduction in section can give rise to rupturing of the
material, this is called a:
a) lap
b) seam
c) burst
d) inclusion

PCN/GEN Appendix B1.3 9 of 9 dated 16th December 2004